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AW NO. 0023E RAS-25FH5/RAC-25YH5 RAS-35FH5/RAC-35YH5 SERVICE MANUAL REFER TO THE FOUNDATION MANUAL TECHNICAL INFORMATION FOR SERVICE PERSONNEL ONLY CONTENTS SPECIFICATIONS ------------------------------------------------------------------- 4 HOW TO USE ----------------------------------------------------------------------- 5 CONSTRUCTION AND DIMENSIONAL DIAGRAM --------------------- 15 MAIN PARTS COMPONENT --------------------------------------------------- 17 WIRING DIAGRAM ---------------------------------------------------------------- 19 CIRCUIT DIAGRAM --------------------------------------------------------------- 20 RAS-25FH5 RAS-35FH5 BLOCK DIAGRAM ----------------------------------------------------------------- 22 BASIC MODE ----------------------------------------------------------------------- 23 REFRIGERATING CYCLE DIAGRAM --------------------------------------- 29 DESCRIPTION OF MAIN CIRCUIT OPERATION ----------------------- 30 SERVICE CALL Q & A ---------------------------------------------------------- 58 TROUBLE SHOOTING ----------------------------------------------------------- 61 PROCEDURE FOR DISASSEMBLY AND REASSEMBLY ------------ 87 PARTS LIST AND DIAGRAM -------------------------------------------------- 89 RAC-25YH5 RAC-35YH5 SPECIFICATIONS DC INVERTER (WALL TYPE) TYPE MODEL POWER SOURCE RAC-35YH5 CAPACITY 1 PHASE, 50 Hz, 220-230V 980 (155 ~ 1,300) 580 (155 ~ 1,080) (A) 3.11-2.97 4.69-4.49 2.50 (0.90 ~ 3.10) 3.50 (0.90 ~ 4.00) (B.T.U./h) 8,530 (3,070 ~ 10,575) 11,942 (3,070 ~ 13,650) (W) 790 (115 ~ 1,120) 1010 (115 ~ 1,300) TOTAL AMPERES NET WEIGHT OUTDOOR UNIT RAS-35FH5 (kW) TOTAL INPUT DIMENSIONS (mm) INDOOR UNIT RAC-25YH5 (W) TOTAL AMPERES CAPACITY HEATING OUTDOOR UNIT RAS-25FH5 1 PHASE, 50 Hz, 220-230V TOTAL INPUT COOLING INDOOR UNIT (A) 3.99-3.82 4.84-4.63 (kW) 3.40 (0.90 ~ 4.40) 4.20 (0.90 ~ 5.00) (B.T.U./h) 11,601 (3,070 ~ 15,695) 14,331 (3,070 ~ 17,745) W 780 750 (+91) 780 750 (+91) H 280 548 280 548 D 220 288 (+47) 220 288 (+47) (kg) 9.5 35 9.5 35 After installation SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT ROOM AIR CONDITIONER INDOOR UNIT + OUTDOOR UNIT FEBRUARY 2007 Hitachi Household Appliances(Wuhu) Co.,Ltd. SAFETY DURING REPAIR WORK 1. 2. In order to disassemble and repair the unit in question, be sure to disconnect the power cord plug from the power outlet before starting the work. t nec n o c t dis lug s u p t, I m r cord utlet. s r i o e F pow wer the the po from If it is necessary to replace any parts, they should be replaced with respective genuine parts for the unit, and the replacement must be effected in correct manner according to the instructions in the Service Manual of the unit. If the contacts of electrical parts are defective, replace the electrical parts without trying to repair them. 3. After completion of repairs, the initial state should be restored. 4. Lead wires should be connected and laid as in the initial state. 5. Modification of the unit by user himself should absolutely be prohibited. 6. Tools and measuring instruments for use in repairs or inspection should be accurately calibrated in advance. 7. In installing the unit having been repaired, be careful to prevent the occurence of any accident such as electrical shock, leak of current, or bodily injury due to the drop of any part. 8. To check the insulation of the unit, measure the insulation resistance between the power cord plug and grounding terminal of the unit. The insulation resistance should be 1M or more as measured by a 500V DC megger. 9. The initial location of installation such as window, floor or the other should be checked for being and safe enough to support the repaired unit again. If it is found not so strong and safe, the unit should be installed at the initial location reinforced or at a new location. 10. Any inflammable thing should never be placed about the location of installation. 11. Check the grounding to see whether it is proper or not, and if it is found improper, connect the grounding terminal to the earth. DANGER WORKING STANDARDS FOR PREVENTING BREAKAGE OF SEMICONDUCTORS 1. Scope The standards provide for items to be generally observed in carrying and handling semiconductors in relative manufacturers during maintenance and handling thereof. (They apply the same to handling of abnormal goods such as rejected goods being returned). 2. Object parts (1) (2) (3) (4) 3. Micro computer Integrated circuits (IC) Field-effect transistors (FET) P.C. boards or the like on which the parts mentioned in (1) and (2) of this paragraph are equipped. Items to be observed in handling (1) Use a conductive container for carrying and storing of parts. (Even rejected goods should be handled in the same way). IC A conductive polyvinyl bag Conductive sponge IC Fig. 1 Conductive Container (2) When any part is handled uncovered (in counting, packing and the like), the handling person must always use himself as a body earth. (Make yourself a body earth by passing one M ohm earth resistance through a ring or bracelet). (3) Be careful not to touch the parts with your clothing when you hold a part even if a body earth is being taken. (4) Be sure to place a part on a metal plate with grounding. (5) Be careful not to fail to turn off power when you repair the printed circuit board. At the same time, try to repair the printed circuit board on a grounded metal plate. Body earth (Elimik conductive band) Clip for connection with a grounding wire 1M Fig. 2 Body Earth –1– (6)Use a three wire type soldering iron including a grounding wire. Metal plate (of aluminium, stainless steel, etc.) Working table Resistor of 1 M (1/2W) Staple Earth wire Bare copper wire (for body earth) Fig. 3 Grounding of the working table Soldering iron Grounding wire Screw stop at the screwed part using a rag plate Fig. 4 Grounding a soldering iron Use a high insulation mode (100V, 10MΩ or higher) when ordinary iron is to be used. (7) In checking circuits for maintenance, inspection or some others, be careful not to have the test probes of the measuring instrument shortcircuit a load circuit or the like. –2– ! CAUTION 1. In quiet operation or stopping the running, slight flowing noise of refrigerant in the refrigerating cycle is heard occasionally, but this noise is not abnormal for the operation. 2. When it thunders near by, it is recommend to stop the operation and to disconnect the power cord plug from the power outlet for safety. 3. The room air conditioner does not start automatically after recovery of the electric power failure for preventing fuse blowing. Re-press START/STOP button after 3 minutes from when unit stopped. 4. If the room air conditioner is stopped by adjusting thermostat, or missoperation, and re-start in a moment, there is occasion that the cooling and heating operation does not start for 3 minutes, it is not abnormal and this is the result of the operation of IC delay circuit. This IC delay circuit ensures that there is no danger of blowing fuse or damaging parts even if operation is restarted accidentally. 5. This room air conditioner should not be used at the cooling operation when the outside temperature is below -10°C (14°F). 6. This room air conditioner (the reverse cycle) should not be used when the outside temperature is below –15°C (5°F). If the reverse cycle is used under this condition, the outside heat exchanger is frosted and efficiency falls. 7. When the outside heat exchanger is frosted, the frost is melted by operating the hot gas system, it is not trouble that at this time fan stops and the vapour may rise from the outside heat exchanger. –3– SPECIFICATIONS RAS-25FH5 RAS-35FH5 RAC-25YH5 RAC-35YH5 PWM DC35V 40 W FAN MOTOR CAPACITOR NO NO FAN MOTOR PROTECTOR NO NO — EU1011DF COMPRESSOR MOTOR CAPACITOR NO NO OVERLOAD PROTECTOR NO YES OVERHEAT PROTECTOR NO YES FUSE (for MICROPROCESSOR) NO 3.0A POWER RELAY NO G4A POWER SWITCH YES NO TEMPORARY SWITCH YES NO SERVICE SWITCH NO YES TRANSFORMER NO NO VARISTOR NO 450NR NOISE SUPPRESSOR NO YES YES(IC) YES(IC) YES NO ---------- 870g MODEL FAN MOTOR COMPRESSOR THERMOSTAT REMOTE CONTROL SWITCH (LIQUID CRYSTAL) REFRIGERANT CHARGING VOLUME (Refrigerant 410A) UNIT WITHOUT REFRIGERANT BECAUSE COUPLING IS FLARE TYPE. PIPES (MAX. 20m) –4– –5– 06K134_RAS_35YH6_001-014_E 5 10/25/06, 1:39 PM SAFETY PRECAUTION “OFF” • Avoid an extended period of direct air flow for your health. PROHIBITION PROHIBITION PROHIBITION –2– • Do not put objects like thin rods into the panel of blower and suction side because the high-speed fan inside may cause danger. • Do not bundle the power cable, pull it, put something on it, heat it, process it, or put it between things. Breakage of the power cable may result. Use of a damaged cable may cause an electrical shock or a fire. leads of the other electric appliance into the socket where this cable is plugged. In addition, wire the cable with some allowances to prevent the cable from stretching. Not doing so will cause an electrical shock, heat generation or fire. PROHIBITION • Please contact your agent if you need to remove and reinstall the unit. Electric shock or fire may occur if you remove and reinstall the unit yourself improperly. • Please contact your agent for maintenance. Improper self maintenance may cause electric shock and fire. • Should abnormal situation arise (like burning smell), please stop operating the unit and remove plug from the socket or turn off the circuit breaker. Contact your agent. Fault, short circuit or fire may occur if you continue to operate the unit under abnormal situation. PRECAUTIONS DURING SHIFTING OR MAINTENANCE • Do not reconstruct the unit. Water leakage, fault, short circuit or fire may occur if you reconstruct the unit by PROHIBITION yourself. • Please ask your sales agent or qualified technician for the installation of your unit. Water leakage, short circuit or fire may occur if you install the unit by yourself. • Please use earth line. Do not place the earth line near water or gas pipes, lightning-conductor, or the earth line of telephone. Improper installation of earth line may cause electric CONNECT EARTH LINE shock. • Be sure to use the specified piping set for R410A. Otherwise, this may result in broken copper pipes or faults. • A circuit breaker should be installed depending on the mounting site of the unit. Without a circuit breaker, the danger of electric shock exists. • Do not install the unit near a location where there is flammable gas. The outdoor unit may catch fire if flammable gas leaks around it. Piping shall be PROHIBITION suitable supported with a maximum spacing of 1m between the supports. • Please ensure smooth flow of water when installing the drain hose. If any failure is found in the drain path, water drops from the indoor and outdoor units, causing wet household effects. • Make sure that a single phase 230V power source is used. The use of other power sources may cause electrical components to overheat PROHIBITION and lead to fire. WARNING • Do not connect the power calbe with an extension cable or do not plug too many CAUTION WARNING Indicates the instructions that must be followed. PRECAUTIONS DURING INSTALLATION • Please keep this manual after reading. This sign in the figure indicates prohibition. • Please read the “Safety Precaution” carefully before operating the unit to ensure correct usage of the unit. Warning” and “ Caution”. The “Warning” section contains • Pay special attention to signs of “ matters which, if not observed strictly, may cause death or serious injury. The “Caution” section contains matters which may result in serious consequences if not observed properly. Please observe all instructions strictly to ensure safety. • The signs indicate the following meanings. (The following are examples of signs.) HOW TO USE CAUTION WARNING • Do not climb on the outdoor unit or put objects on it. PROHIBITION –3– • This appliance is not intended for use by young children or infirm persons unless they have been adequately supervised by a responsible person to ensure that they can use this appliance safely. • Young children should be supervised to ensure that they do not play with the appliance. DON’T TOUCH • Do not touch the air outlet, bottom surface and aluminum fin of the outdoor unit. You may get hurt. • Do not touch the refrigerant pipe and connecting valve. Burns may result. DON’T TOUCH PROHIBITION PROHIBITION • If the amount of heat in the room is above the cooling or heating capability of the unit (for example: more people entering the room, using heating equipments and etc.), the preset room temperature cannot be achieved. • This appliance especially indoor unit cleaning must be performed by authorized personnel only. Consult your sales agent. Using a commercially available detergent or similar can damage the plastic parts or clog the drain pipe, causing water to drip with potential electric shock hazard. PROHIBITION • When operating the unit with the door and windows opened, (the room humidity is always above 80%) and with the air deflector facing down or moving automatically for a long period of time, water will condense on the air deflector and drips down occasionally. This will wet your furniture. Therefore, do not operate under such condition for a long time. PROHIBITION • Do not place plants or animals directly under the air flow as it is bad for the plants or animals. PROHIBITION • Do not wash the unit with water or place a water container such as a vase on the indoor unit. Electrical leakage could be present and cause electric shock. • Please ensure that outdoor mounting frame is always stable, firm and without defect. If not, the outdoor unit may collapse and cause danger. PROHIBITION STRICTLY OBSERVE PRECAUTIONS • Do not direct the cool air coming out from the air-conditioner panel to face household heating apparatus as this may affect the working of apparatus such as the electric kettle, oven etc. • When operating the unit with burning equipments, regularly ventilate the room to avoid oxygen insufficiency. PROHIBITION PROHIBITION PROHIBITION • Do not attempt to operate the unit with wet hands, this could cause fatal accident. • The product shall be operated under the manufacturer specification and not for any other intended use. DON’T WET PROHIBITION • During thunder storm, disconnect the plug top or turn off the circuit breaker. • Spray cans and other combustibles should not be located within a meter of the air outlets of both indoor and outdoor units. As a spray can’s internal pressure can be increased by hot air, a rupture may result. “OFF” • Do not use any conductor as fuse wire, this could cause fatal accident. PRECAUTIONS DURING OPERATION –6– –4– 280 780 750 RAS-25FH5, RAS-35FH5 RAC-25YH5, RAC-35YH5 548 HEIGHT (mm) 288 220 DEPTH (mm) About the outdoor unit: • When “Stop” is selected during operation of the indoor unit, the fan of the outdoor unit continues turning for 10 to 60 seconds to cool the electric parts down. • In heating operation, condensate or water due to defrosting will flow. Do not cover the drain port of the outdoor unit because such water may freeze in the chilly area. • When the outdoor unit is hung on the ceiling, install the bush and drain pipe on the drain port and drain water. Air inlets (Rear and left sides) Piping and Wiring Drain hose Drains the dehumidified water from the indoor unit to the outdoor during “cooling” or “dehumidifying” operation. WIDTH (mm) MODEL MODEL NAME AND DIMENSIONS Drain port (Bottom) Earth terminal (Lower section of the side) Air outlet When “heating” operation is performed, cool air blows and when “cooling” or “dehumidifying” operation is performed, warm air blows. OUTDOOR UNIT Remote controller Send out operation signal to the indoor unit. So as to operate the whole unit. (Refer page 6) Indoor unit indicators Light indicator showing the operating condition. (Refer page 5) Horizontal deflector Vertical deflector (Air Outlet) (Refer page 15) Front panel TIMER LAMP (Orange) This lamp lights when the timer is working. CAUTION TEMPORARY SWITCH ● Use this switch to start and stop when the remote controller does not work. ● This temporary operation will be at the most recent setting made. (The unit will immediately go into automatic operation once power is switched on.) –5– Attaching the air cleansing and deodorizing filters (Accessories) to the filter frame. • Attach the air cleansing and deodorizing filters to the frame by gently compress its both sides and release after insertion into filter frame. • The cooling capacity is slightly weakened and the cooling speed becomes slower when the air cleansing and deodorizing filters Frame are used. • Air cleansing and deodorizing filters are washable and reusable up to 20 times by using vacuum cleaner or water rinse under running tap water. When you want to renew it, please ask your sales agent. The power is saved by turning off the power switch (or the circuit breaker when the power is supplied from the outdoor unit). ✩ If the power stays on and the unit is not operated, power is slightly consumed in the control circuit. Turn off the circuit breaker or pull out the power plug if the unit is not be operated for a long period. POWER SWITCH FILTER LAMP (Green) When the device is operated for a total of about 200 hours, the FILTER lamp lights indicates that it is time to clean the filter.The lamp goes out when the “ (AUTO SWING)” button is pressed while the operation is stopped. OPERATION LAMP (Yellow) This lamp lights during operation. The OPERATION LAMP flashes in the following cases during heating. (1) During preheating For about 2-3 minutes after starting up. (2) During defrosting Defrosting will be performed about once an hour when frost forms on the heat exchanger of the outdoor unit, for 5-10 minutes each time. INDOOR UNIT INDICATIONS INDOOR UNIT Air filter To prevent dust from coming into the indoor unit. (Refer page 16) NAMES AND FUNCTIONS OF EACH PART NAMES AND FUNCTIONS OF EACH PART ENGLISH –7– 06K134_RAS_35YH6_001-014_E 7 10/25/06, 1:39 PM AUTO SWING ON TIMER OFF TIMER TIMER SELECTOR TIMER SET TIME START/STOP START (RESERVE) STOP (CANCEL) SLEEPING LOW MED HI FAN SPEED FAN COOL DEHUMIDIFY HEAT AUTO –6– • Do not put the remote controller in the following places. • In direct sunlight • In the vicinity of a heater. • Handle the remote controller carefully. Do not drop it on the floor, and protect it from water. • Once the outdoor unit stops, it will not restart for about 3 minutes (unless you turn the power switch off and on or unplug the power cord and plug it in again). This is to protect the device and does not indicate a failure. • If you press the FUNCTION selector button during operation, the device may stop for about 3 minutes for protection. Precautions for Use ● SLEEP button Use this button to set the sleep timer. ● TEMPERATURE buttons Use these buttons to raise or lower the temperature setting. (Keep pressed, and the value will change more quickly.) ● TIME button Use this button to set and check the time and date. ● RESET button Press this button after the batteries are replaced or when some irregular operation is found. ● FUNCTION selector Use this button to select the operating mode. Every time you press it, the mode (AUTO) to (HEAT) to (DEHUMIDIFY) to (COOL) and will change from to (FAN) cyclically. ● FAN SPEED selector ● AUTO SWING button ● TIMER control Use these buttons to set the timer. ● OFF-TIMER button Select the turn OFF time. ● ON-TIMER button Select the turn ON time. ● RESERVE button Time setting reservation. ● CANCEL button Cancel time reservation. ● Signal emitting window/transmission sign Point this window toward the indoor unit when controlling it. The transmission sign blinks when a signal is sent. ● Display This indicates the room temperature selected, current time, timer status, function and intensity of circulation selected. ● START/STOP button Press this button to start operation. Press it again to stop operation. ● AUTO SWING button Controls the angle of the horizontal air deflector. ● FAN SPEED selector This determines the fan speed. Every time you press this button, the intensity of circulation will change from (AUTO) to (HI) to (MED) to (LOW). (This button allows selecting the optimal or preferred fan speed for each operation mode.) • This controls the operation of the indoor unit. The range of control is about 7 meters. If indoor lighting is controlled electronically, the range of control may be shorter, in some cases, the control signal may not be received. This unit can be fixed on a wall using the fixture provided. Before fixing it, make sure the indoor unit can be controlled from the remote controller. • Handle the remote controller with care. Dropping it or getting it wet may compromise its signal transmission capability. • After new batteries are inserted into the remote controller, the unit will initially require approximately 10 seconds to respond to commands and operate. REMOTE CONTROLLER NAMES AND FUNCTIONS OF EACH PART (START/STOP) button. Press the –7– (FAN SPEED) button, AUTO and LOW is available. • The preset temperature and the actual room temperature may vary somewhat depending on conditions. Press the temperature button and the temperature setting will change by 1°C each time. You can raise or lower the temperature setting as necessary by maximum of 3°C. ■ As the settings are stored in memory in the remote controller, you only have to press the (START/STOP) button next time. Press the • When AUTO has been selected, the device will automatically determine the mode of operation, HEAT or COOL depending on the current room temperature. • When AUTO is first selected, the device will determine the current room temperature and select the proper operation mode accordingly. • When the air conditioner has adjusted the room's temperature to the near preset temperature, it will begin to monitor operation. If the room temperature subsequently changes, the air conditioner will once again select the appropriate operation (heating or cooling) to adjust the temperature to the preset temperature. The monitoring operation range is + 3°C relative to the preset temperature. • If the mode automatically selected by the unit is not satisfactory, manually change the mode setting (heat, dehumidify, cool or fan). START Operation starts with a beep. STOP Press the button again to stop operation. 1 Press the FUNCTION selector so that the display indicates the (AUTO) mode of operation. The device will automatically determine the mode of operation, HEAT or COOL depending on the initial room temperature. The selected mode of operation will change when the room temperature varies. AUTOMATIC OPERATION • If there is a power failure, operation will be automatically restarted when the power is resumed with previous operation mode and airflow direction. (As the operation is not stopped by remote controller.) • If you intend not to continue the operation when the power is resumed, switch off the power supply. When you switch on the circuit breaker, the operation will be automatically restarted with previous operation mode and airflow direction. Note: 1. If you do not require Auto Restart Control, please consult your sales agent. 2. Auto Restart Control is not available when Timer or Sleep Timer mode is set. ■ Auto Restart Control VARIOUS FUNCTIONS –8– 06K134_RAS_35YH6_001-014_E 8 10/25/06, 1:39 PM : Quiet. : More quiet. (MED) (LOW) The temperature setting and the actual room temperature may vary somewhat depending on conditions. ■ As the settings are stored in memory in the remote controller, you only have to press the (START/STOP) button next time. –8– (If the piping length used is longer than usual, frost will likely to form.) The maximum time for defrosting is 20 minutes. During defrosting operation, the operation lamp blinks in cycle of 3 seconds on and 0.5 second off. Defrosting will be performed about once an hour when frost forms on the heat exchange of the outdoor unit, for 5~10 minutes each time. ■ Defrosting : Economical as the room will become warm quickly. But you may feel a chill at the beginning. (HI) Set the desired room temperature with the TEMPERATURE buttons (the display indicates the setting). : The fan speed changes automatically according to the temperature of the air which blows out. (FAN SPEED) button (AUTO) Set the desired FAN SPEED with the (the display indicates the setting). (START/STOP) button. Heating operation starts START Press the STOP with a beep. Press the button again to stop operation. 3 2 1 Press the FUNCTION selector so that the display indicates (HEAT). • Use the device for heating when the outdoor temperature is under 21°C. When it is too warm (over 21°C), the heating function may not work in order to protect the device. • In order to keep reliability of the device, please use this device above -15°C of the outdoor temperature. HEATING OPERATION (START/STOP) button. –9– • Dehumidifying takes place with a target temperature which is slightly lower than the room temperature setting. (However, target temperature is 16°C for a temperature setting of 16°C.) If the room temperature becomes lower than the target value, operation stops. If the room temperature becomes higher than the target value, operation restarts. • The preset room temperature may not be reached depending on the number of people present in the room conditions. ■ Dehumidifying Function ■ When you want to change the operation mode, please use the FUNCTION selector. ■ Set the desired temperature is available. ■ You also can use the FUNCTION selector to select this operation. START Press the STOP 1 Press the FUNCTION selector so that the display indicates (DEHUMIDIFY). The FAN SPEED is set at LOW automatically. The FAN SPEED button does not work. Use the device for dehumidifying when the room temperature is over 16°C. When it is under 15°C, the dehumidifying function will not work. DEHUMIDIFYING OPERATION –9– 06K134_RAS_35YH6_001-014_E 9 10/25/06, 1:39 PM : Economical as the room will become cool quickly. : Quiet. : More quiet. (HI) (MED) (LOW) The temperature setting and the actual room temperature may vary somewhat depending on conditions. Set the desired room temperature with the TEMPERATURE buttons (the display indicates the setting). : The FAN SPEED is HI at first and varies to MED automatically when the preset temperature has been reached. (FAN SPEED) button (AUTO) Set the desired FAN SPEED with the (the display indicates the setting). Press the FUNCTION selector so that the display indicates (COOL). – 10 – ■ As the settings are stored in memory in the remote controller, you only have to press the (START/STOP) button next time. (START/STOP) button. Cooling operation starts Press the with a beep. Press the button again to stop operation. The cooling START function does not start if the temperature setting is higher than the current room temperature (even though the (OPERATION) STOP lamp lights). The cooling function will start as soon as you set the temperature below the current room temperature. 3 2 1 Use the device for cooling when the outdoor temperature is -10 to 42°C. If humidity is very high (over 80%) indoors, some dew may form on the air outlet grille of the indoor unit. COOLING OPERATION (FAN SPEED) button. (START/STOP) button. Fan operation starts with a For the cooling operation For the heating operation – 11 – • Operation starts in the “HI” mode to reach the preset temperature. • As room temperature approaches the preset temperature, fan speed automatically switches to “LOW”. • The fan speed will automatically change according to the temperature of discharged air. • As room temperature reaches the preset temperature, a very light breeze will blow. FAN SPEED (AUTO) … When the AUTO fan speed mode is set in the cooling/heating operation: Press the : Quiet. : More quiet. (LOW) : The strongest air blow. (MED) (HI) Press the Press the FUNCTION selector so that the display indicates (FAN). START beep. STOP Press the button again to stop operation. 2 1 You can use the device simply as an air circulator. Use this function to dry the interior of the indoor unit at the end of summer. FAN OPERATION – 10 – 06K134_RAS_35YH6_001-014_E 10 10/25/06, 1:39 PM Stop 1 PM Press the (RESERVE) button. 3 AM PM Press the (ONTIMER) button so that the (OFF) mark lights and the (ON) mark blinks. AM Press the (ON-TIMER) button. The (ON) mark blinks on the display. AM You can set only one of the OFF-timer, ON-timer and ON/OFF-timer. NOTE – 12 – Point the signal window of the remote controller toward the indoor unit, and press the (CANCEL) button. The (RESERVED) sign goes out with a beep and the (TIMER) lamp turns off on the indoor unit. PM Start 1 D Press the (OFF-TIMER) (OFF) mark blinks button. The on the display. M with the TIMER control button. 1 Set the current month and day Set the turn-off time with the TIMER control button. 2 Stop (OFFTIMER) button so that (OFF) mark the blinks. 1 Press the How to Cancel Reservation • The device will turn on (off) and off (on) at the designated times. • The switching occurs first at the preset time that comes earlier. • The arrow mark appearing on the display indicates the sequence of switching operations. Start ON/OFF-Timer Stop D You can set the device to turn off at the present time. Start OFF-Timer M After you change the batteries; Time, Day, Month The device will turn on at the designated times. ON-Timer CANCEL RESERVE ON TIMER OFF TIMER TIME, DAY, MONTH (current time, day, month) HOW TO SET THE TIMER Example: The device will turn off at 11:00p.m. The setting of turn-off time is now complete. AM Example: The device will turn on early so that the preset temperature be almost reached at 7:00 a.m. The setting of the turn-on time is now complete. AM PM Example: For heating, the device will turn off at 10:30 p.m., and then turn on early so that the preset temperature be almost reached at 7:00 a.m.; for cooling and dehumidifying, it will simply turned on at 7:00 a.m. The settings of the turn on/off times are now complete. Point the signal window of the remote controller toward the indoor unit, and press the (RESERVE) button. The (ON) mark starts lighting instead of flashing and the (RESERVED) sign lights. A beep occurs and the (TIMER) lamp lights on the indoor unit. 5 PM Point the signal window of the remote controller toward the indoor unit, and press the (RESERVE) button. The (ON) mark starts lighting instead of flashing and the (RESERVED) sign lights. A beep occurs and the (TIMER) lamp lights on the indoor unit. 3 3 • To check the current time setting, press the (TIME) button twice. The setting of the current time is now complete. Point the signal window of the remote controller toward the indoor unit, and press the (RESERVE) button. (RESERVED) The (OFF) mark starts lighting instead of flashing and the sign lights. A beep occurs and the (TIMER) lamp lights on the indoor unit. PM • The time indication will disappear automatically in 10 seconds. – 13 – • As the time settings are stored in memory in the remote controller, you only have to press the (RESERVE) button is order to use the same settings next time. • The timer may be used in three ways: off-timer, on-timer and ON/OFF (OFF/ON)-timer. Set the current time at first because it serves as a reference. AM PM Set the turn-on time with the TIMER control button. 4 AM Set the turn-on time with the TIMER control button. 2 PM PM 4 Press the (TIME) button again. The time indication star ts lighting instead of flashing. Example: The current time is 1:30p.m. 3 Set the current time with the TIMER control button. Set the turn-off time with the TIMER control button. 2 AM PM Set the (TIME) button. 2 – 11 – 06K134_RAS_35YH6_001-014_E 11 10/25/06, 1:39 PM 3 hours Sleep timer off 2 hours Sleep timer AM 7 hours Start The device will be turned off by the sleep timer and turned on by on-timer. Example: If you set 3 hours sleep time at 11:38 p.m., the turn-off time is 2:38 a.m. For heating: In this case, the device will turn off in 2 hours (at 1:38 a.m.) and turn on early so that the preset temperature will be almost reached at 6:00 next morning. – 14 – If you set the sleep timer when the off-time or on/offtimer has been set earlier, the sleep timer becomes effective instead of the off - or on/off-timer set earlier. NOTE Point the signal window of the remote controller toward the indoor unit, and press the (CANCEL) button. The (RESERVED) sign goes out with a beep and the (TIMER) lamp turns off on the indoor unit. AM AM 1 Set the ON-timer. 2 Press the (SLEEP) button and set the sleep timer. How to Cancel Reservation ● SLEEP 1 hour Indication Sleep Timer: The device will continue working for the desired number of hours and then turn off. Point the signal window of the remote controller toward the indoor unit, and press the SLEEP button. The timer information will be displayed on the remote controller. The TIMER lamp lights with a beep from the indoor unit. When the sleep timer has been set, the display indicates the turn-off time. Sleep Timer Mode Set the current time at first if it is not set before (see the pages for setting the current time). Press the (SLEEP) button and the display changes as shown below. HOW TO SET THE SLEEP TIMER Left side: side: Hold Hold the the third Left blade from from the left end blade of the the air air deflector deflector to of adjust the the direction. direction. The adjust pull for for the the blade blade is pull marked. marked. Right side: Hold the third blade from the right end of the air deflector to adjust the direction. The pull for the blade is marked. Hold Hold the vertical air deflector as shown in the figure and adjust the the conditioned conditioned air to the left and right. Adjustment Adjustment of the conditioned air to the left and right. CAUTION CAUTION •• In “Cooling” operation, do not keep the horizontal air deflector swinging for a long time. Some dew may form on the horizontal horizontal air deflector and dew may drop. (AUTO button is is pressed pressed once, once, the the horizontal horizontal •• IfIf the the ““ (AUTO SWING)” SWING)” button air again, the the air deflector deflector swings swings up up and and down. down. IfIf the the button button is is pressed pressed again, deflector stops in its current position. Several seconds (about 66 deflector stops in its current position. Several seconds (about seconds) may be required before the deflector starts to move. seconds) may be required before the deflector starts to move. •• Use adjusting range range Use the the horizontal horizontal air air deflector deflector within within the the adjusting shown shown in in the the right. right. •• When air deflector deflector When the the operation operation is is stopped, stopped, the the horizontal horizontal air moves and stops at the position where the air outlet closes. Adjustment Adjustment of of the the conditioned conditioned air air in in the the upward upward and and downward downward directions. directions. The angle The horizontal horizontal air air deflector deflector is is automatically automatically set set to to the the proper proper angle suitable The deflector deflector can can be be swung swung up up and and suitable for for each each operation. operation. The down using the the down continuously continuously and and also also set set to to the the desired desired angle angle using (AUTO ““ (AUTO SWING)” SWING)” button. button. about 30° about 30° about 45° about 45° Vertical Vertical When heating When heating about 60° about 60° about about 15 15°° Vertical Vertical When When cooling, cooling, dehumidifying dehumidifying CAUTION CAUTION Install the new batteries. Install The direction of the batteries should match the marks The in the the case. case. in Remove Remove the cover as shown in the figure and take out the the old old batteries. – 15 – 1. Do Do not not use use new and old batteries, or different kinds of 1. batteries together. batteries 2. Take Take out the batteries when you do not use the remote 2. controller for 2 or 3 months. controller 2 1 Push and pull to the direction of arrow. HOW TO EXCHANGE THE BATTERIES IN THE REMOTE CONTROLLER 2 1 ADJUSTING ADJUSTING THE THE AIR AIR DEFLECTORS DEFLECTORS ENGLISH – 12 – CAUTION • Set the filter with “FRONT” mark facing front, and slot them into the original state. • After attaching the filters, push the front panel at three arrow portions as shown in figure and close it. Vacuum dust from the air filter using vacuum cleaner. If there is too much dust, wash the filter with a detergent and rinse it thoroughly. After that, dry it in the shade. Open the front panel carefully and remove the filter. – 16 – • Do not wash with hot water at more than 40°C. The filter may shrink. • When washing it, shake off moisture completely and dry it in the shade; do not expose it directly to the sun. The filter may shrink. • Don't operate the unit without filter. Fault may occur if you continue. 3 2 1 PROCEDURE When the filter indicator lamp comes on, be sure to clean the filter. By doing so, the power rates are saved. In case the air filter is full of dust, the air flow will decrease and the cooling capacity will be reduced. Further, noise may occur. Be sure to clean the filter following the procedure below. 1. AIR FILTER Cleaning and maintenance must be carried out only by qualified service personal. Before cleaning, stop operation and switch off the power supply. CAUTION MAINTENANCE Step Shaft – 17 – • Switch off the power plug or turn off the circuit breaker. • Run the unit by setting the operation mode to (FAN) and the fan speed to HI for about half a day on a fine day, and dry the whole of the unit. Air Blow 3. MAINTENANCE AT BEGINNING OF LONG OFF PERIOD B E N ZIN E A C I D T H IN NER • Move the shafts of the left and right arms into the steps in the unit and securely insert them into the holes. Hole Attaching the Front Panel • Do not splash or direct water to the body of the unit when cleaning it as this may cause short circuit. • Never use hot water (above 40°C), benzine, gasoline, acid, thinner or a brush, because they will damage the plastic surface and the coating. CAUTION • When the front panel is fully opened with both hands, push the right arm to the inside to release it, and while closing the front panel slightly, put it out forward. Removing the Front Panel Method of removing the front panel. Be sure to hold the front panel with both hands to detach and attach it. • Wipe the water thoroughly. If water remains at indicators or signal receiver of indoor unit, it causes trouble. • When front panel is not removed, wipe it with a soft dry cloth. Wipe the remote controller thoroughly with a soft dry cloth. • Remove the front panel and wash with clean water. Wash it with a soft sponge. After using neutral detergent, wash thoroughly with clean water. 2. CLEANING OF FRONT PANEL ENGLISH – 13 – 06K134_RAS_35YH6_001-014_E 13 10/25/06, 1:39 PM – 18 – • When the timer has been programmed, the unit will not operate even if the set time is reached unless the unit receives a signal from the remote controller. Confirm that timer programming is complete (beep) and the TIMER lamp of the indoor unit lights. (SLEEP) button is pressed while the ON/OFF timer is programmed, the sleep timer takes priority. • If the • During sleep timer operation, the fan speed sets to (LOW) regardless of the preset speed. The remote (LOW) setting. controller display indication will remain unchanged even with the TIMER PROGRAMMING/SLEEP TIMER OPERATION • When fan speed, room temperature are set with the remote controller before starting manual operation and the buttons are released, the indication of settings will go off in 10 seconds and only the operation mode will be displayed. button while the unit is in operation will let the protective circuit work so that the unit will • Pressing the not operate for approximately 3 minutes. • During heating operation, the indoor unit’s color indicator lamp may flash with no air emitted for a while. (HI) fan speed or want to make the unit operation • If you feel cold wind during heating operation with the (AUTO) setting is recommended. quieter after the room is heated, use of (LOW) setting, the unit’s cooling capability will lower slightly. • With the • With the (LOW) setting, the unit’s heating capacity will vary with the operating conditions. VARIOUS FUNCTIONS • If the heat present in a room exceeds the unit’s cooling capacity (for example, if there are many people in the room or other heating appliances are used), the preset room temperature may not be reached. Cooling and Dehumidifying Capabilities • This room air conditioner utilizes a heat pump system that absorbs CAUTION exterior heat and brings it into a room to be heated. As the ambient Do not use a stove temperature gets lower, heating capability will also lower. In such a or any other situation, the inverter work to increase compressor rpm to keep the h i g h t e m p e r a t u r e unit’s heating capability from decreasing. If the unit’s heating perfor- devices in proximity PROHIBITION mance is still unsatisfactory, other heating appliances should be used to the indoor unit. to augment this unit’s performance. • The air conditioner is designed to heat an entire room so that it may take some time before you feel warm. Timer operation is recommended for effective preheating ahead of the desired time. Heating Capability CAPABILITIES INFORMATION WARNING WARNING WARNING Check to see if the power plug is securely inserted into the wall socket. If the power plug is not inserted into the wall socket securely or becomes hot, an electric shock or fire may result. If dust or dirt is found on the power plug, clean the plug and insert it into the wall socket. Check to see if the mounting frame has rusted excessively or if the outdoor unit has tilted or become unstable. It could collapse or fall, causing injury. Check to see if the unit’s earth line has been connected correctly. If the earth line is disconnected or faulty, unit failure or electric shock hazard may result. When it does not cool well. When it does not heat well. Clicking noise Rustling noise Squeaking noise Hissing or fizzy sounds During heating, the operation indicator blinks and air blow stops – 19 – <Operation start> The unit is preparing to blow warm air. Please wait. <In operation> The outdoor unit is defrosting. Please wait. Refrigerant flow noise in the pipe or valve sound generated when flow rate is adjusted. Noise generated when the unit expands or contracts due to temperature changes. Noise generated with the indoor unit fan’s rpm changing such as operation start times. Noise of the motorized valve when the unit is switched on. ■ The following phenomena do not indicate unit failure. • Is the air filter blocked with dust? • Is the set temperature suitable? • Have horizontal air deflectors been adjusted to their correct positions according to the operation mode selected? • Are the air inlets or air outlets of indoor and outdoor units blocked? • Is the fan speed “LOW”? When it does not operate. Is the fuse all right? Is the voltage extremely high or low? Is the circuit breaker “ON”? Is the power plug inserted? Do you have any power cut? • Do the batteries need replacement? • Is the polarity of the inserted batteries correct? CHECK THE FOLLOWING POINTS • • • • • (Remote controller display is dim or blank.) If the remote controller is not transmitting a signal. CONDITION WHEN ASKING FOR SERVICE, CHECK THE FOLLOWING POINTS. AFTER SALES SERVICE AND WARRANTY 3 2 1 PLEASE CHECK THE FOLLOWING POINTS EVERY EITHER HALF YEARLY OR YEARLY. CONTACT YOUR SALES AGENT SHOULD YOU NEED ANY HELP. REGULAR INSPECTION – 14 – 06K134_RAS_35YH6_001-014_E 14 10/25/06, 1:39 PM ( ) Contact your sales agent immediately if the following phenomena should occur: • The circuit breaker switches off or the fuse blows frequently. • The switch operation is not stable. • Foreign matter or water accidentally enters the unit interior. • The power cord gets excessively hot or its insulation is torn or stripped. • TIMER lamp on the indoor unit display blinks. As the nature of the failure can be identified by the blinking cycle, check the blinking cycle before turning off the circuit breaker. Noise of the ventilation fan sucking in air present in the drain hose and blowing out dehumidifying water that had accumulated in the condensed water collector. For details, consult your sales agent. Operation noise changes due to power variations according to room temperature changes. Mist is generated as the air within the room is suddenly cooled by conditioned air. Water generated during defrosting operation evaporates and steam is emitted. Caused as the smells and particles of smoke, food, cosmetics, etc. present in room air become attached the unit and blown off into the room again. Defrosting is underway (as the heating operation is stopped, the microcomputer checks frost accumulated in the outdoor unit and instructs the unit to perform automatic defrosting if necessary). Shows preheating or defrosting operation is underway. As the protective circuit or preheat sensor operates when unit operation is stopped during preheating and then restarted, or when operation mode is switched from cooling to heating, the lamp continues to blink. Actual room temperature may deviate slightly from the remote controller's temperature setting depending on the number of people in the room, indoor or outdoor conditions. – 20 – Please note: On switching on the equipment, particularly when the room light is dimmed, a slight brightness fluctuation may occur. This is of no consequence. The conditions of the local Power Supply Companies are to be observed. • Please contact your sales agent immediately if the air conditioner still fails to operate normally after the above inspections. Inform your agent of the model of your unit, production number, date of installation. Please also inform him regarding the fault. Notes • In quiet operation or stopping the running, the following phenomena may occasionally occur, but they are not abnormal for the operation. (1) Slight flowing noise of refrigerant in the refrigerating cycle. (2) Slight rubbing noise from the fan casing which is cooled and then gradually warmed as operation stops. • The odor will possibly be emitted from the room air conditioner because the various odor, emitted by smoke, foodstuffs, cosmetics and so on, sticks to it. So please clean the air filter and the evaporator regularly to reduce the odor. • If the unit still fails to operate normally after performing the above inspections, turn the circuit breaker off, or pull the power plug out, and contact your sales agent immediately. Does not reach the temperature setting The OPERATION lamp is blinking. The outdoor unit continues to operate even if operation is stopped. Odors Mist emission Steam emitted from the outdoor unit Changing operation noise Perking noise CONSTRUCTION AND DIMENSIONAL DIAGRAM MODEL RAS-25FH5, RAS-35FH5 INDOOR UNIT – 15 – CONSTRUCTION AND DIMENSIONAL DIAGRAM MODEL RAC-25YH5, RAC-35YH5 OUTDOOR UNIT Handle Handle Air outlet Air Suction grill Rear side Holes for anchor bolt (2 – ø12 x 6 slots for ø8.0 bolt) Notch for anchor bolt (for 2 – ø8.0 bolt) Fixing hole Drain hole Drain hole More than 300 More than 100 More than 50 Service space – 16 – More than 200 MAIN PARTS COMPONENT THERMOSTAT Thermostat Specifications MODEL RAS-25FH5, RAS-35FH5 THERMOSTAT MODEL IC OPERATION MODE TEMPERATURE °C (°F) COOL HEAT INDICATION 16 ON 16.7 (62.1) 18.7 (65.7) OFF 16.0 (60.8) 19.3 (66.7) INDICATION 24 ON 24.7 (76.5) 26.7 (80.1) OFF 24.0 (75.2) 27.3 (81.1) INDICATION 32 ON 32.7 (90.9) 34.7 (94.5) OFF 32.0 (89.6) 35.3 (95.5) FAN MOTOR Fan Motor Specifications RAS-25FH5, RAS-35FH5 MODEL POWER SOURCE DC 5V, 35V DC 140 ~ 350V 25W 40W OUTPUT RED 35V 140~ 350V BLK 0V WHT 5V CONNECTION RAC-25YH5, RAC-35YH5 YEL 0 ~ 5V M BLU FG 0V 15V 0~6V 0~15V RED BLK WHT YEL BLU (Control circuit built in) BLU : BLUE GRY : GRAY BLK : BLACK YEL : YELLOW ORN : ORANGE PNK : PINK BRN : BROWN GRN : GREEN VIO : VIOLET WHT : WHITE RED : RED MAIN ELECTRIC COMPONENTS FOR OUTDOOR UNIT NAME RATING APPLICABLE MODELS REVERSING VALVE COIL 135 Ω (20 ˚C) RAC-25YH5, RAC-35YH5 REACTOR L1 13 (mH), 0.224 Ω RAC-25YH5, RAC-35YH5 REACTOR L2 25.5 (mH), 0.37 Ω RAC-25YH5, RAC-35YH5 FILM CAPACITOR 45 (μF) RAC-25YH5, RAC-35YH5 – 17 – M COMPRESSOR MOTOR Compressor Motor Specifications MODEL RAC-25YH5, RAC-35YH5 ITEM COMPRESSOR TYPE EU1011DF POWER SOURCE DC 220 ~ 350 V OUTPUT 800W (U) M WINDING M (V) RESISTANCE (Ω) WHITE M YELLOW 20°C 2M=1.069 75°C 2M=1.300 (W) RED FRONT SIDE OF OUTDOOR UNIT ! CAUTION When the refrigerating cycle has been operated for a long time with the capillary tubes clogged or crushed or with too little refrigerant, check the color of the refrigerating machine oil inside the compressor. If the color has been changed conspicuously, replace the compressor. – 18 – WIRING DIAGRAM ! CAUTION The marked parts ! are very important ones for safety. ! ! ! ! ! ! ! L (A) N (B) ! ! – 19 – CIRCUIT DIAGRAM RAS-25FH5, RAS-35FH5 – 20 – MODEL RAC-25YH5, RAC-35YH5 PQ1 PQ2 PQ401 PQ402 PQ403 PQ404 PQ701 RED RED RED SELF-CHECK SELF-MODE SERVICE SW AX-8T11 – 21 – BLOCK DIAGRAM MODEL RAS-25FH5 / RAC-25YH5 RAS-35FH5 / RAC-35YH5 INDOOR UNIT OUTDOOR UNIT Outdoor DC fan motor Power source 1ø 50Hz 220-230V POWER SWITCH POWER RELAY RECTIFIER HARMONICS IMPROVEMENT CIRCUIT IPM Inrush current Protection circuit DC compressor motor Rotor magnetic pole position detection circuit Wireless receive circuit Room temperature thermistor Indoor microcomputer (AX-7R13) Indicating lamp Heat exchanger thermistor lp Buzzer circuit ld Filter. Operation. Timer. Auto sweep motor for Air deflector ls Overheat thermistor Defrost thermistor Outdoor microcomputer (AX-8T11) Remote controller Outdoor temperature thermistor Relay drive circuit Electric expansion valve Temporary switch Indoor/Outdoor interface circuit Initial setting circuit Indoor/Outdoor interface circuit Reversing valve control circuit DC fan motor drive circuit Reversing valve coil Reset circuit Microcomputer clock circuit Indoor DC fan motor Power circuit Reset circuit – 22 – RAS-25FH5, RAS-35FH5 25 26 27 button 26 26 28 – 23 – – 24 – Table 1 Thermo judgment Item Temperature Thermo judgment Room temperature Thermo judgment Thermo judgment Outdoor temperature Thermo judgment CLMXTP (ON) (OFF) (ON) (OFF) Table 2 Compressor speed Calculated compressor speed 25FH5 1900 min–1 2400 min–1 2900 min–1 3300 min–1 3300 min–1 button 35FH5 1900 min–1 2400 min–1 2900 min–1 3400 min–1 3800 min–1 Temperature difference (with shift value) Compressor speed NOTE (9) Reversing valve (cooling “on” mode) 2min. 30sec. 2min. 30sec. Notes: (1) Condition for entering into Cool Dashed mode. When fan set to “Hi” or “Auto mode” and temperature difference between indoor temperature and set temperature has a corresponding compressor speed (calculated value in Table 2) larger than CMAX. (2) Cool Dashed will release when i) a maximum 25 minutes is lapsed and ii) room temperature is lower than set temperature –3°C (thermo off) and iii) when room temperature has achieved setting temperature –1°C then maximum Cool Dashed time will be revised to 20 minutes. And iv) indoor fan is set to Lo and Med fan mode and v) change operation mode. (3) During Cool Dashed operation, thermo off temperature is set temperature (with shift value) –3°C. After thermo off, operation continue in Fuzzy control mode. (4) Compressor minimum “ON” time and “OFF” time is 3 minutes. (5) During normal cooling mode, compressor maximum speed CMAX will maintain for 60 minutes if indoor temperature is lower than CLM XTP. No time constrain if indoor temperature is higher than CLMXTP. (6) When fan speed setting on remote control is “Hi” or “Auto” mode, and both room and outdoor temperatures (data based on out door unit) meet temperature judgment (Off) shown in the table 1, the compressor speed will be limited to CKYMAX. (7) When fan is set to “Med”, compressor speed will be limited to CJKMAX. (8) When fan is set to “Lo”, compressor speed will be limited to CBEMAX. (9) During Cool Dashed, when room temperature reaches set temperature –1°C compressor speed is actual speed x DWNRATEC. – 25 – 1.66°C 2.00°C 2.33°C 2.66°C 3.00°C 30°C 32°C 32°C 33°C Cooling Sleep Operation Dehumidifying Operation Room temperature 7 hr + 1 hr + Set to 7 hours Operation lamp Timer lamp Remote control (Sleep) ON Hi Med Indoor fan Lo See basic operation button –0.66˚C –1.33˚C Sleep button Start Stop Sleep Lo Outdoor fan Horizontal air Shut deflector Horizontal Facing down Compressor speed 2 min 30 sec. Min Min Notes: (1) The sleep operation starts when the sleep button is pressed. (2) When the sleep button is set, the maximum compressor speed is limited to CBEMAX, and the indoor fan is set to "sleep Lo". (3) The indoor fan speed does not change even when the fan speed mode is changed. (4) If sleep operation is canceled by the cancel button or sleep button, all data is cleared. STARCP Notes: (1) The operation is done assuming as the preset temperature = (room temperature at the time) – (2°C). (2) The indoor fan is operated in the “Lo” mode. During thermo OFF indoor fan will be OFF for 5 minutes and ON for 1 minute. (3) When the operation is started by the themostat turning ON, the start of the indoor fan is delayed 32 seconds after the start of compressor operation. (4) The compressor is operated forcedly for 3 minutes after operation is started. (5) The minimum ON time and OFF time of the compressor are 3 minutes. Dehumidifying Sleep Operation Cooling Defrost 7hr 1hr Set to 7 hours Sleep button Operation lamp Timer lamp Remote control (Sleep) ON Hi Indoor fan See basic Med operation Lo Sleep Lo Outdoor fan Shut Horizontal air deflector Horizontal Facing down Reversing valve (cooling "on" model) Compressor speed 1min. SDMAX or SDRPM Notes: (1) The sleep operation starts when the sleep button is pressed. (2) When the sleep button is set, the indoor fan is set to “sleep Lo”. (3) The indoor fan speed does not change even when the fan speed mode is changed. (4) If sleep operation is canceled by the cancel button or sleep button, all data is cleared. – 26 – Table 3 Compressor speed 1.33˚C. Calculated compressor speed 0.66˚C. SFTDSW Basic Heating Operation Heating set temperature (remote control set temperature (+)) 18˚C TWMAX Dash period 25FH5 1300 min–1 1800 min–1 2300 min–1 2800 min–1 3300 min–1 35FH5 1300 min–1 1800 min–1 2300 min–1 2800 min–1 3300 min–1 3800 min–1 3800 min–1 3.00°C 3.33°C 3800 min–1 4300 min–1 3.66°C –1 –1 4.00°C 3800 min Fan speed set to "auto" Stop Star t Start/stop button Preheating judgment Max. 3 min. Preheating released Stop 4500 min 10sec. 30sec. Med Thermo OFF 30sec. 30sec. 30sec. 30sec. Control by heat exchanger temperature 30sec. 10sec. 10sec. 15sec. Control by heat exchanger temperature Lo 10sec. 30sec. 30sec. Control by heat exchanger temperature 10sec. Control by heat exchanger temperature 15sec. Control by heat exchanger temperature 15sec. Ultra-Lo Operation lamp 1 min. WMAX2 Compressor speed Max. (WMAX) NOTE (10) Rating (WSTD) Wtd 3000 WMIN 0 3min. 15sec. 15sec. 15sec. 15sec. 1.66°C 2.00°C 2.33°C 2.66°C Notes: page 47 & 49 for each constant in 1. See the data in Table 1-Table 2 on capital letters in the diagrams. Preheat released 30sec. 30sec. Hi Start Thermo OFF Ultra-Hi Indoor fan Stop Thermo OFF Thermo judgment Defrost signal Start Temperature difference (with shift value) 15sec. Outdoor fan Reversing valve (cooling "on" model) Notes: (1) Condition for entering into Hot Dashed mode. When fan set to “Hi” or “Auto mode” and i) Indoor temperature is lower than 18°C, and ii) outdoor temperature is lower than 10°C, and iii) Temperature difference between indoor temperature and set temperature has a corresponding compressor speed (calculated value in Table 3) larger than WMAX. (2) Hot Dashed will release when i) Room temperature has achieved the set temperature + SFTDSW. ii) Thermo off. (3) During Hot Dashed operation, thermo off temperature is set temperature (with shift value) +3°C. After thermo off, operation continue in Fuzzy control mode. (4) Compressor minimum “ON” time and “OFF” time is 3 minutes. (5) During normal heating mode, compressor maximum speed WMAX will maintain for 120 minutes if indoor temperature is higher than 18°C. No time limit constrain if outdoor temperature is lower than 4°C. (6) During Hotkeep or Defrost mode, indoor operation lamp will blink at interval of 0.5 seconds “ON” and 0.5 second “OFF”. (7) When heating mode starts, it will enter into Hotkeep mode if indoor heat exchanger temperature is lower than YNEOF + 0.33°C. (8) When fan is set to “Lo”, compressor speed will be limited to WBEMAX. When fan is set to "Med", compressor speed will be limited to WJKMAX. (9) In “Ultra-Lo” fan mode, if indoor temperature is lower than 18°C, indoor fan will stop. If indoor temperature is higher than 18°C + 0.33°C, fan will continue in “Ultra-Lo” mode. During Hotkeep or Defrost mode, fan will continue in “Ultra-Lo” mode. (10) During Hot Dashed, when room temperature reaches set temperature + SFTDSW compressor speed is actual speed x DWNRATEW. – 27 – Heating Sleep Operation Reversing Valve Defrosting Preheating released Sleep button Reversing valve (cooling "on" model) 2min. 30sec. Sleep Lo Notes: (1) The defrosting inhibit period is set as shown in the diagram below. When defrosting has finished once, the inhibit period is newly set, based on the outdoor temperature when the compressor was started. During this period, the defrost signal is not accepted. (2) If the difference between the room and outdoor temperature is large when defrosting is finished, the maximum compressor speed (WMAX) or (WMAX2) can be continued for 120 minutes maximum. (3) The defrosting period is 12 minutes maximum. (4) When operation is stopped during defrosting, it is switched to auto refresh defrosting. (5) Auto refresh defrosting cannot be engaged within 15 minutes after operation is started or defrosting is finished. Upper limit WBEMAX Notes: (1) The sleep operation starts when the sleep button is pressed. (2) When the sleep button is set, the maximum compressor speed is limited to WBEMAX, and the indoor fan is set to "sleep Lo". (3) The indoor fan speed does not change even when the fan speed mode is changed. (Sleep Lo) (4) When defrosting is to be set during sleep oepration, defrosting is engaged and sleep operation is restored after defrosting. (5) If sleep operation is cancelled by the cancel button or sleep button, all data is cleared. – 28 – RAS-25FH5 / RAC-25YH5 RAS-35FH5 / RAC-35YH5 – 29 – DESCRIPTION OF MAIN CIRCUIT OPERATION MODEL RAS-25FH5, RAS-35FH5 1. Reset Circuit 5V Microcomputer 2 R552 1 C522 5 C524 C521 R551 7 RES 3 IC521 0V Fig. 1-1 Power "ON" Voltage Power "OFF" 5.0V Voltage supply to pin 2 of IC521 Reset enter at 4.2V Reset release at 4.4V Voltage Voltage at pin 7 of microcomputer 5.0V Fig. 1-2 The reset circuit initializes the microcomputer program when power is ON or OFF. Low voltage at pin 7 resets the microcomputer and Hi activates the microcomputer. When power “ON” 5V voltage rises and reaches 4.4V, pin 1 of IC521 is set to “Hi”. At this time the microcomputer starts operation. When power “OFF” voltage drops and reaches 4.2V, pin 1 of IC521 is set to “Low”. This will RESET the microcomputer. – 30 – 2. Receiver Circuit 12V Q141 VDD L201 R212 C212 C211 0V R141 ZD141 0V 0V IRR 13 VOUT R211 R611 C611 RECEIVER I/P Microcomputer 0V GND 0V Fig.2-1 IRR (light receiver unit) receives the infrared signal from the wireless remote controller. The receiver amplifies and shapes the signal and outputs it. 3. Buzzer Circuit 12V R721 IC711 Microcomputer Buzzer output 30 BZ BZ1 1 16 Fig.3-1 Buzzer circuit When the buzzer sounds, an approx 3.9kHz square signal is output from buzzer output pin T of the microcomputer. After the amplitude of this signal has been set to 12Vp-p by IC711, it is applied to the buzzer. The piezoelectric element in the buzzer oscillates to generate the buzzer’s sound. Metal diaphragm Sound wave Pizoelectric element V Fig. 3-2 Buzzer Operation – 31 – V 4. Auto Sweep Motor Circuit 12V Auto sweep motor for horizontal air defectors CN4 IC711 Microcomputer 18 7 10 17 6 11 16 5 12 4 13 Rotor 15 Fig.4-1 Fig. 4-1 shows the Auto sweep motor drive circuit; the signals shown in Fig.4-2 are output from pin E~H of microcomputer. Step width : 10ms Micro computer pins Horizontal air deflectors 1 2 3 4 5 6 7 8 15 16 17 18 Fig.4-2 Microcomputer Output Signals As the microcomputer’s outputs change as shown in Fig.4-2, the coils of the auto sweep motor is excite to turn the rotor. Table 4-1 shows the rotation angle of horizontal air deflectors. Table 4-1 Auto sweep Motor Rotation Rotation angle per step ( Horizontal air deflectors ) 0.0882 Time per step (ms.) 10 – 32 – 5. Initial Setting Circuit (IC401) • When power is supplied, the microcomputer reads the data in IC401 or IC402 (E2PROM) and sets the preheating activation value and the rating and maximum speed of the compressor, etc. to their initial values. • Data of self-diagnosis mode is stored in IC401 or IC402; data will not be erased even when power is turned off. 5V 8 7 6 5 0V C401 0V 5V R403 1 2 3 4 R404 5V Microcomputer 27 SCL 26 SDA } External ROM IC401 or IC402 (E2PROM) 0V Fig. 5-1 6. Power Supply Fig. 6-1 First, 35V power which operates the indoor unit is generated by the power source section of the outdoor unit and supplied to the indoor unit through the C and D lines of the connecting cable. Second, use the DC/DC converter and the 35 V power supply from the outdoor unit to generate 12 V control power, which drives the stepping motor during the operation. In addition, use the regulator IC 121 to generate 5 V power required for driving the micro computer and controlling fan motor. If the terminal block was overheated due to a connecting cable improper connection, the thermal fuse built in the terminal block will burnt to shut off the 12 V line and stop the operation of the indoor unit. Then, the outdoor unit cannot be communicated with the indoor unit and a communication error occurs (the outdoor LD301 will blink 9 times), stop all operations. – 33 – 7. Fan Motor Drive Circuit CN10 35V 0V Micro computer B A DC fan 24 motor output R751 M 5V Fan motor C751 DC fan motor Speed 14 feedback 0V C631 R631 C 0V Voltage at point A Waveform Fig. 7-1 T1 T2 T1 = Low speed T2 = High speed T2 T1 Voltage at point B Waveform T1 Voltage at point C Waveform T2 Fig. 7-2 • For the point A , 15.7 kHz PWM pulse will be output from the pin N on the micro computer as shown in Fig. 7-2. The pulse range will vary with different command speed. • The pulse is converted into the analog voltage by the R751 and C751 and applied to the fan motor as the speed (1400) command voltage. Fig. 7-3 shows the relation between the voltage at the Speed point B and the speed. (Some differences will occur due (min ) to the condition of the unit.) • The fan motor outputs the feedback pulse of the speed, 0 1 2 3 4 5 which is input into the pin D on the micro computer. This Voltage at point B (V) pulse is equivalent to a frequency of 12/60 speed. Fig. 7-3 (Example: 1000 min-1 x 12/60 = 200 Hz) The micro computer monitors the frequency and adjusts the output pulse range of the pin N so as to keep the command speed. • If the feedback pulse is 100 min-1 or less due to a locked fan motor or failure, the fan output will be stopped temporarily as fan lock error. After 10 seconds, restart the output of the pulse. If fan lock error is detected twice within 30 minutes, all units are stopped and the unit will come in the failure mode. (The timer lamp will blink 10 times.) -1 – 34 – MODEL RAC-25YH5, RAC-35YH5 1. The electrical parts for the outdoor unit is composed of two P.W.B. (a power P.W.B. and main P.W.B.) and a harmonics improvement circuit as shown in Fig. 1-1. • Main P.W.B. This P.W.B. is equipped with the rectification diode, DC fan motor control circuit and the circuits around the micro computer which take various controls. • POWER P.W.B. This P.W.B. is equipped with the noise filter, ICP power circuit, interface circuit, smoothing capacitor, expansion valve control circuit and four-way valve control circuit. • HARMONICS IMPROVEMENT CIRCUIT This circuit is composed of the capacitor at the bottom of the electrical parts box and two reactors attached to the BULKHEAD. POWER P.W.B. MAIN P.W.B. RECTIFIER SWITCHING POWER SUPPLY. C INVERTER CIRCUIT B INTERFACE CIRCUIT SMOOTHING CAPACITOR N.F. FILTER ICP CIRCUIT IPM A COMPRESSOR HARMONICS IMPROVEMENT CIRCUIT INVERTER CONTROLCIRCUIT FAN MOTOR CONTROL CIRCUIT D POSSITON DETECTIVE CIRCUIT RESET CIRCUIT REVERSING VALVE CONTROL CIRCUIT MICRO COMPUTER ELECTRIC EXPANSION VALVE CONTROL CIRCUIT Fig. 1-1 – 35 – THERMISTOR DETECTION CIRCUIT 2. Power circuit This circuit is to convert the power from AC which is provided from the terminal A and B to DC voltage. And produces an AC current which does not exceed the harmonic amplitude limit of the IEC61000-3-2. When the compressor is stopped, the AC voltage becomes about 300 V and while the compressor operates, it is about 280 V. Fig. 2-1 Main parts (1) DB2 The DB2 rectifies the AC voltage. The possible causes for the DB2 failure are as follows. The 15 A fuse may be blown out or the IPM for the main P.W.B. may have a failure. In such a case, check the 15 A fuse for blowout and replace the main P.W.B. if necessary. (2) DB3, L1, C023 and L2 The DB3, L1, C023 and L2 shape waveform of the input current. When the current runs through the L1 is taken for I1 and the current runs through the L2 is taken for I2 as shown in Fig. 2-2, I1 becomes an input current to the capacitor which peak value was crushed by the L1 and I2 becomes a resonance current which causes the LC resonance using the L2 and C023. By combining the I1 and I2, the input current from the main power shapes a waveform shown in the right side of Fig. 2-3, indicating that the waveform is similar to sine wave. The more the waveform is similar to the sine wave, the lower the harmonic current becomes. If the C023 has any failure, the protection unit activates and the C023 in open mode. In such a case, replace the failed parts. I1 DB3 L1 IS I1 + C023 L2 I2 I2 Fig. 2-3 Fig. 2-2 – 36 – (4) DB1 and C41 The DB1 rectifies the input voltage and the C41 smoothes it for the control power supply. If the units above have any failure, the control power supply won’t operate. In such a case, replace the power P.W.B. Input Voltage Voltage 0V 0V Smoothed Voltage (3) C021 and C022 This smoothes the voltage rectified for operating the compressor. When the input voltage is taken for the sine wave as shown in the top of Fig. 2-4, it is rectified by the DB2 and becomes the waveform as shown in the middle of Fig. 2-4. After that, the voltage is smoothed by the C021 and C022, and becomes the waveform shown in the bottom of Fig. 2-4. 0V (5) C001 to C003, C011, L101, and L102 Fig. 2-4 They absorb electrical noise generated during operation of compressor, and also absorb external noise entering from power line to protect electronic parts. Be sure to connect the earth cable between the indoor unit and the outdoor unit. Otherwise, the noise filter circuit won’t operate properly. (6) SA1 and VS1 to VS3 These surge absorber and varistors absorb external power surge such as induced thunder. Be sure to connect the earth cable between the indoor unit and the outdoor unit. Otherwise, the surge absorber and the varistors won’t operate. (7) R002 and R007 The resistor R002 protects the rush current when the power is turned on while the resistor R007 protects the rush current when the compressor starts. When the R002 has any failure, the control power supply won’t operate. When the R007 has any failure and a strong rush current is generated, the DB2, C021 or C022 may be damaged. – 37 – 3. Indoor/Outdoor Interface Circuit The interface circuit superimposes an interface signal on the DC 35V line to perform communications between indoor and outdoor units. This circuit consists of a transmitting circuit which superimposes an interface signal transmit from the microcomputer on the DC 35V line and a circuit which detects the interface signal on the DC 35V line. Communications are performed alternatively transmitting and receiving. 3-1 Communication signal from outdoor microcomputer to indoor microcomputer. At first outdoor microcomputer will send a request signal (SDO) to indoor microcomputer. 38 KHz of carrier signal is generated and modulated by the request signal (SDO) from the outdoor microcomputer pin A. This signal is superimposed to DC 35V line via C801 and L801. To prevent erroneous reception, the outdoor microcomputer is designed so that it cannot receive a signal while it is outputting a request signal. The receiving circuit in the indoor unit consists of a comparator and transistor. The interface signal from the outdoor unit on the DC 35V line is supplied to C821, where DC components are eliminated, and is then shaped by the comparator. The shaped signal is detected by diode, amplified by amp, and output to pin i of the indoor microcomputer. Fig. 3-2 shows the waveforms at each component when data is transferred from the outdoor microcomputer to the indoor microcomputer. 3-2 Communication signal from indoor microcomputer to outdoor microcomputer. The request signal (SDO) generates by indoor microcomputer is output to pin j , and amplifies by Q801. I/F signal approx. 38 kHz is generated by comparator, then modulated by the signal from pin j of indoor microprocessor. This modulated I/F signal is then amplified and superimposed to DC 35V line via L801 and C802 of indoor interface circuit. Fig. 3-3 shows the waveforms at each component when data is transferred from outdoor microcomputer to indoor microcomputer. The circuit operation of the outdoor receiving circuit is same as indoor receiving circuit. – 38 – Fig. 3-1 shows the interface circuit used for the indoor and outdoor microcomputers to communicate with each other. Control P.W.B. Fig. 3-1 – 39 – 5V Outdoor microcomputer Pin 11 0V Pin 68 5V 0V Indoor microcomputer Pin 50 5V Pin 49 5V 0V 0V 35V 35V DC line 100ms. Leader 33ms. 1 frame Fig. 3-2 Voltages Waveforms of Indoor / Outdoor Microcomputers (Outdoor to Indoor Communications) Outdoor microcomputer Pin 11 0V Pin 68 5V 0V 5V Indoor microcomputer Pin 50 0V Pin 49 5V 0V 35V 35V DC line 4.95ms. Transmit/receive switching time 33ms. 1 frame Fig. 3-3 Voltages Waveforms of Indoor / Outdoor Microcomputers (Indoor to Outdoor Communications) – 40 – – 41 – 0 (33.3ms.) 7 Character No. Bit No.=0 Leader (100ms.) 0 34(V) 35(V) 36(V) Example When the outdoor message is all 0s and indoor message is all 1s: (3)Communications waveforms When reset (approx.10ms.) 7 0 2 (33.3ms.) Outdoor message 1 (33.3ms.) (2)Indoor microcomputer to outdoor microcomputer (HIC) When reset (approx.100ms.) (1)Outdoor microcomputer (HIC) to indoor microcomputer Serial Communications Format during Normal Communications 7 7 Fig. 3-4 0 (33.3ms.) No. Bit No.=0 Transmit/ receive switching time (4.95ms.) 0 3 (33.3ms.) 7 0 1 (33.3ms.) 70 2 (33.3ms.) Indoor message 7 0 3 (33.3ms.) 7 Leader (100ms.) – 42 – 1 0 7 6 5 4 2 3 2 1 0 6 5 Fan(0 LSB) Capacity code(3 MSB) Capacity code(2) Capacity code(1) Capacity code(0 LSB) Indoor in-operation bit Operation mode(2 MSB) Operation mode(1) Operation mode(0 LSB) Contents Contents 7 3 2 1 0 Multi-bit 4 1 0 Character No. Bit No. (1)Outdoor message Serial Communications Data During forced operation Fan(1) 1 Defrost request signal 3 4 Self-diagnosis(0 LSB) 2 5 Self-diagnosis(1) Fan(2 MSB) 1 6 Self-diagnosis(2) 2-way valve 0 7 Self-diagnosis(3 MSB) Reversing valve 7 0 Outside temperature(0 LSB) Compressor ON 6 1 Outside temperature(1) Compressor command speed(0 LSB) 5 2 Outside temperature(2) Compressor command speed(1) 4 3 Outside temperature(3) Compressor command speed(2) 0 4 Outside temperature(4) Compressor command speed(3) 3 5 Outside temperature(5) Compressor command speed(4) 2 6 Outside temperature(6) Compressor command speed(5) 1 7 Outside temperature(7 MSB) Compressor command speed(6) 0 0 Compressor during operation Compressor command speed(7 MSB) Character No. Bit No. 1 Compressor during operation (2)Indoor message 2 Actual compressor rotation speed(0 LSB) 15/20(A) 0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 2 0 0 0 1 3 Actual compressor rotation speed(1) 1/0 0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 0 4 Actual compressor rotation speed(2) Data 5 Actual compressor rotation speed(3) OVL up 0 1/0 1/0 1/0 0 1/0 0 3 0 7 6 5 4 7 6 Actual compressor rotation speed(4) 2 Actual compressor rotation speed(5 MSB) 3 0 1 2 3 3 Fan-7-step request 0 0 Compressor minimum rotation speed(0 LSB) 0 4 Compressor minimum rotation speed(1) 1/0 1/0 1/0 1/0 0 5 Compressor minimum rotation speed(2) Data 7 6 Compressor minimum rotation speed(3) 0 Compressor minimum rotation speed(4 MSB) 4. IPM (Intelligent Power Module) • Fig.4-1 shows the intelligent power module and its peripheral circuit. The three transistors on the positive E side are called the upper arm, and the three transistors on the negative D side, the lower arm. E E IP limitter E Fig. 4-1 Intelligent power module circuit (U+ is ON, V- is ON) – 43 – Intelligent power module switches power supply current according to position of the compressor motor rotor. The switching order is as shown in Fig. 4-2. At point E: U+ is ON, V- is ON (circuit in Fig. 4-1) At point F: U+ is chopped (OFF), V- is ON (circuit in Fig. 4-4) E V + W + F U+ V+ Upper arm transistor Time Lower arm transistor U- T V- W- Fig. 4-2 Switching order of power module Upper arm transistor is controlled to ON/OFF by 3.3kHz chopper signal. Rotation speed of the compressor is proportional to duty ratio (ON time/ ON time + OFF time) of this chopper signal. Time T in Fig. 4-2 shows the switching period, and relation with rotation speed (N) of the compressor is shown by formula below; N = 60/2 X 1/T Fig. 4-3 shows voltage waveform at each point shown in Figs. 4-1 and 4-4. First half of upper arm is chopper, second half is ON, and first half of lower arm is chopper, second half is ON. U + U - transistor ON transistor chopped Voltage at 280V-300V Chopping period T Chopping period (300μ sec.) ON Upper arm transistor Current at Fig. 4-3 Voltage waveform at each point When power is supplied U+→ V- , because of that U+ is chopped, current flows as shown below; (1) When U+ transistor is ON: U+ transistor → U coil → V coil → V- transistor → DC current detection resistor → Point B (Fig. 4-1) (2) When U+ transistor is OFF: (by inductance of motor coil) U coil → V coil → V- transistor → U- diode → Point A (Fig. 4-4) – 44 – Fig. 4-4 Power module circuit (U+ is OFF, V– is ON) Since current flows at point B only when U+ transistor and V- transistor are ON, the current waveform at point B becomes intermittent waveform as shown in Fig. 4-3. Since current at point B is approximately proportional to the input current of the air conditioner, input current is controlled by using DC current (Id) detection resistor. <Reference> If power module is defected, self diagnosis lamps on the MAIN P.W.B. may indicate as shown below: Table 4-1 Self-diagnosis Self-diagnosis lamp and mode Ip (peak current cut) LD301 Blinks 2 times Abnormal low speed rotation LD301 Blinks 3 times Switching incomplete LD301 Blinks 4 times Fig. 4-5 – 45 – • IPM drive circuit The inverter driving device (IGBT) and the drive circuit are built in the IPM. The IPM receives the signal from the microcomputer and convert it to 0 – 15 V signal to drive the IGBT. When the unit operates at low speed, a chopper signal is emitted from the micro computer as shown in Fig. 4-6. (0 to 5 V) The signal is converted to 0 – 15 V at inside the IPM and transmitted to the gate of the transistor (IGBT) in each phase to drive the IGBT. When abnormal peak current was detected while the inverter is driving, the IPM outputs the Fail signal immediately from the pin S and forces the lower arm transistor to shut off at the same time. In this step, the Q501 is turned on and the input signal of the upper arm is also shut off through the D501 and D502, so that all signals to the IGBT are shut off. This signal is also distributed to microcomputer (pin G) as a Lo signal to stop the drive signal and blink the self diagnosis lamp as two time. When the peak current is detected, the IPM keeps the lower arm off for about 4mS and the drive signal into stand-by state. 3 minutes after this state, the micro computer outputs the drive signal and restarts the operation. 120 Drive signal at point C V U V U 120 W V 120 U 5V 0V W U V W Drive signal at point D U 15V 0V V W U V W Fig. 4-6 – 46 – W 120 V U 120 W V 5. Power Circuit for P.W.B. • Fig. 5-1 shows the power circuit for P.W.B. AC220-230V • In the power circuit for P.W.B., power supply for microcomputer, peripheral circuits, and IPM driver circuit and, as well as DC 35V, are produced by switching power circuit. • Switching power circuit performs voltage conversion effectively by switching transistor IC1 to convert DC 330V voltage to high frequency of about 20kHz to 200kHz. – 47 – • The voltage specification of the power circuit is as follows. <Check points> Output Voltage spec. Main load Measuring points + – 12V 11-13V 5V Potential failure modes MAIN P.W.B. (CN3, CN4) R701 (“12V” display) C21 (“12V” display) R006 (“0V” display) J27, J30 The unit won’t operate MAIN P.W.B. error 4.5-6V MAIN P.W.B. (CN3, CN4) D30 anode (“5V” display) R006 (“0V” display) J25 J27, J30 The unit won’t operate MAIN P.W.B. error B-12V 11-16V Expansion valve R25 (“B-12V” display) R25 (“B-0V” display) LD301 blinks 5 times; Expansion valve error 15V 14-17V DC fan motor (CN24) MAIN P.W.B. (CN3, CN4) C06+ side C06- side LD301 blinks 3 times, 35V 33.5-38V Indoor unit electrical parts (Terminal C,D) Reversing valve (CN2) D20 cathode (“C-35V” display) Terminal C (blown line) J5, J17 Terminal D (red line) Indoor unit won’t operate • Check each voltage. If each voltage meets the voltage specification above, the power circuit is normal. • If any error is found after checking, remove all loads and recheck each voltage. If no error is found in this step, the power circuit is normal. Check the removed loads. If any error is found in this step, the power circuit has any failure. Replace the power P.W.B. A short-circuited load may cause an output error not only in the load but also in the others. Be sure to check all outputs of the loads. Be sure to wait 15 minutes or more in order to discharge all the remaining voltage in the circuit to connect/disconnect the wiring, otherwise, the components may be damaged. • The failures of the loads are as follows. Failed output Possible causes Criterion 35V Reversed connection of the cable. Electrical part for the indoor unit has a failure. Connect the cable correctly. Remove the connection cable and measure the voltage. If the voltage is correct, check the electrical parts for the indoor unit. Remove the CN2 and measure the voltage. If the voltage is correct, check the reversing valve. Short-circuited reversing valve 15V DC fan motor error Main P.W.B. error 12V, 5V Main P.W.B. error Remove the CN24 and measure the voltage. (connect the CN3.) If the voltage is correct, check the DC fan motor. Also, check the main P.W.B. 1 A fuse for blow out in this step. Remove the CN3 and CN4 and meaure the voltage. If the voltage is correct, check the main P.W.B. Remove the CN3 and CN4 and meaure the voltage. If the voltage is correct, check the main P.W.B. – 48 – 6. Microcpomputer's Peripheral Circuits 6-1. Overload control circuit (OVL control circuit) Overload control is to decrease the speed of the compressor and reduce the load when the load on the air conditioner increases to an overload state, in order to protect the compressor, electronic components and power breaker. Overloads are judged by comparing the DC current level and set value. Fig.6-1 shows the overload control system configuration and Fig. 6-4 is a characteristic diagram on overload judgement values. There are two types of control which has named IS OVL and ID OVL. IS OVL is limiting the whole input of this room air conditioner system through the current sensor CT1 in order to keep the maximum rating of components by reading total operating current. ID OVL is watching and limits the compressor current through the detection resistor, which is built in IPM in order to control the compressor reliability. Since the compressor reliability is related with its speed, the ID OVL value is also linked with the compressor speed. Fig. 6-2 shows an ID OVL limitation curve. All of OVL operation values were programmed into EEPROM memory. Compressor Microcomputer EEPROM Motor current (ID) Detection resistor A-D converter ID OVL value Motor control Amplifier process Smoother A-D converter Detection transformer CT1 Whole current (IS) Fig. 6-1 Overload Control System – 49 – IS OVL value IPM Detection N Resistor 37 DC Current Direct Current P 32 35 42 R003 R004 29 Q501 R513 Power P.W.B. R514 R906 0V R905 C919 R613 Microcomputer 0V R608 R241 5V C222 R612 0V C224 5V D204 R222 CN4A 61 I S 0V 0V 0V 60 I d 0V C218 1 R247 C217 0V 11 C010 0V D001 R005 17 I p 0V R221 CN4B C009 R006 0V R248 IC4 0V 0V CT1 7 5 D204 6 R249 5V R245 59 V d 0V C210 0V R287 12V D208 5V 2 1 3 0V R289 C215 R284 R286 56 Reset output R288 R252 0V 0V 0V C204 C226 R285 R292 IC5 48 Reset 0V Main P.W.B. Fig. 6-2 (1) IS OVL Current transformer CT1 reads the input flowing current and detected to the microcomputer as a voltage signal. Receiving this, the microcomputer converts it to a digital signal and compares it with the internal data to judge whether or not overload control is required. Fig. 6-3 shows the rotation speed control. When the voltage at pin u of the microcomputer exceeds the set value, the microcomputer decreases the rotation speed of the compressor and reduces the load. Voltage at microcomputer pin 61 Rotation speed of compressor Command rotation speed Actual rotation speed Decelerating Accelerating Decelerating Accelerating Fig. 6-3 (2) ID OVL Fig. 6-2. The filter consisting of R245 and C217 removes high harmonic frequencies from the voltage generated by the current flowing to Detection resistor; R245 and C217 average the voltage. This voltage is then input to IC4 pin 5 and supplied to microcomputer pin t . The microcomputer compares this input with the set value, and if the input exceeds the set value, it enters overload control status. DC current The set Value is determined by the amplification of the voltage amp. circuit Amplification : high → DC current : low Amplification : low → DC current: high Fig. 6-4 shows the rotation speed control. When the voltage at pin t of the microcomputer exceeds the set value, the microcomputer decreases the rotation speed of the compressor and reduces the load. Judgment value according to rotation speed (internal judgment value) Rotation speed Fig. 6-4 – 50 – R003,R004,R608,R613, detect the DC voltage at the power circuit. The microcomputer receives a DC voltage and applies correction to the overload set value so the DC current will be low when the DC voltage is high. (Since the load level is indicated by the DC voltage multiplied by DC current, R247, R248, R249 are provided to perform the same overload judgement even when the voltage varies.) Fig. 6-5 (3) Start current control It is required to maintain the start current (DC current) constant to smooth the start of the DC motor of the compressor. RAC-25YH5, RAC-35YH5 uses software to control the start current. The start current varies when the supply voltage varies. This control method copes with variations in the voltages as follows. 1. Turns on the power module’s U+ and V- transistors so the current flows to the motor windings as shown in Fig. 6-6. 2. Varies the turn-ON time of the U+ transistor according to the DC voltage level and the start is controlled so the start current is approx. 10A . IPM P DC current U W Compressor motor U V W DC Voltage N V U V Detection resistor Fig. 6-6 – 51 – W 6-2. Reset Circuit MAIN P.W.B. 12V 5V D208 0V 2 0V 0V C225 R285 R292 C226 1 0V 3 Microcomputer R289 8 R286 R284 C215 R287 56 RESET OUT. R252 48 RESET C204 IC5(1/2) 0V 0V R288 Fig. 6-7 The reset circuit initializes the microcomputer program when Power is “ON” from “OFF”. Low voltage at pin h resets the microcomputer, and HI activates the microcomputer Fig. 6-7 shows the reset circuit and Fig. 6-8 shows waveform at each point when power is turned on and off. When power is turned on, 12V line and 5V line voltages rise and 12V line voltage reaches 10.9V an reset voltage input to pin h of microcomputer is set to Hi. Reset voltage will be hold “Hi” until the 12V line voltage drops to 9.90V even though the power shuts down. Power is ON Voltage (V) 12 12V line 10.9V 5V line 6 Reset voltage Power is OFF Voltage (V) 0 12 6 Time 12V line 9.9V 5V line Reset voltage 0 Time Fig. 6-8 – 52 – 7. Temperature Detection Circuit MAIN P.W.B. +5V O.H. thermistor 1 CN8 R304 62 OH 2 +5V C304 R301 DEF. thermistor 1 0V CN9 0V R305 2 63 DEF +5V Outdoor temperature thermistor 1 Microcomputer C303 R302 0V CN10 0V R306 2 Outdoor 64 temperature C302 R303 0V 0V Fig. 7-1 The Over heat thermistor circuit detects the temperature at the surface of the compressor head, the Defrost. thermistor circuit detects the defrosting operation temperature. A thermistor is a negative resistor element which has the characteristics that the higher (lower) the temperature, the lower (higher) the resistance. When the compressor is heated, the resistance of the Over heat thermistor becomes low and voltage to a pin v of microcomputer is increased. Microcomputer compares the voltage at pin v with the internal set value, if it is exceeded the set value microcomputer judges that the compressor is overheated and stops operation. When frost forms on the outdoor heat exchanger, the temperature at the exchanger drops abruptly. Therefore the resistance of the Defrost. thermistor becomes high and the voltage at pin w of microcomputer drops. If this voltage becomes lower than the set value stored inside, the microcomputer starts defrosting control. During defrosting operation the microcomputer transfers the defrosting condition command to the indoor microcomputer via the circuit interface. The microcomputer always reads the outdoor temperature via a thermistor (microcomputer pin x ), an transfers it to the indoor unit, thus controlling the compressor rotation speed according to the value set at the EEPROM in the indoor unit, and switching the operation status (outdoor fan on/off, etc.) in the dehumidifying mode. The following shows the typical values of outdoor temperature in relation to the voltage: Table 7-1 Outdoor temperature ( ) 10 R303 Voltage (V) 1.19 0 10 20 30 40 1.69 2.23 2.75 3.22 3.62 <Reference> When the thermistor is open, in open status, or is disconnected, microcomputer pins v–x are approx. 0V; when the thermistor is shorted, they are approx. 5 V, and LD301 blinks seven times. However, an error is detected only when the OH thermistor is shorted; in such a case, the blinking mode is entered 12 minutes after the compressor starts operation. – 53 – 8. Reversing valve control circuit Power P.W.B. C-35V MAIN P.W.B. 12V Reversing valve CN2 2 R701 D701 PQ701 4 CN4A CN4B Microcomputer Q701 R705 6 DC voltmeter or multimeter 6 24 R706 V D-0V Fig. 8-1 Reversing valve control circuit will switch reversing valve ON/OFF (cooling ON) according to instruction from indoor microcomputer depending on the operation condition shows in Table 8-1. Voltage at Q701 (between Collector and Emittor) in each operation condition is approximately as shown in Table 8-1 when measured by multimeter. Table 8-1 Collector voltage of Q701 Operation condition Cooling Heating Dehumidifying General operation of cooling About 0.8V In normal heating operation About 35V MAX. rotation speed instructed by indoor microcomputer after defrost is completed About 35V Defrosting About 0.8V Sensor dry About 0.8V – 54 – 9. Electric expansion valve control circuit POWER P.W.B. MAIN P.W.B. 5V CN15 B-12V B-12V B-12V 6 R403 R404 R401 5 4 15 3 Electric expansion valve Microcomputer 1 8 14 2 2 PQ404 6 R293 11 R294 10 4 8 3 9 CN4B 4 5 12 13 C401 2 PQ403 11 7 + 1 PQ402 3 10 1 PQ401 R295 R296 39 Valve4 40 Valve3 41 Valve2 42 Valve1 CN4A IC6 B-0V Fig. 9-1 • To drive the expansion valve, use the B-12 V output. Use a 4-phase coil and feed power to the phases 1 and 2, then switch over the filed poles to control the opening of the valve. • The reference between conducting phase switch over direction and the open/close direction are shown in Table 9-1. When the power is turned on, approx. 0.9 V is applied to the CN15 and the pins (1 to 4) and when no power is supplied, 12 V is applied. When the power is reset, the expansion valve starts initial operation for 5 to 10 seconds. • During the initial operation, measure each pin of the CN15 (1 to 4) with a multimeter. If no change is found around 0.9 V or 12V in this step, the expansion valve or the micro computer has failure. • The logic waveform during the operating of the expansion valve is shown in Fig. 9-2. Table 9-1 CN15 Lead Pin No. wire Drive status 1 2 3 4 5 6 7 8 ON ON OFF OFF OFF OFF OFF ON Yellow OFF ON ON ON OFF OFF OFF OFF Orange OFF OFF OFF ON ON ON OFF OFF OFF OFF OFF OFF OFF ON ON ON White Blue Operation mode 1 2 3 4 5 6 7 8 VALVE CLOSE 8 7 6 5 4 3 2 1 VALVE OPEN 12V Pin No. 0.9V 50ms. 75ms. 200ms. Fig. 9-2 – 55 – 10. Outdoor DC Fan Motor control circuit This model uses DC Fan Motor which has a controller circuit built in the Motor. This DC Fan Motor will rotate by control voltage apply to Vsp input. (Voltage range: 1.7 to 7V DC. Vsp high : Faster ; Vsp low : slower ; Vsp lower than 1.7V : stop Motor will output FG pulse by following this motor revolution. Outdoor microcomputer will output PWM control signal from £ by following the instruction from indoor microcomputer. This PWM control signal will convert to Vsp voltage by smoothing circuit (R242 & C209). Fan motor will start to rotate when Vsp was proceeding over than 1.7V, and generate FG pulse by rotation speed. FG pulse will feed back to Outdoor microcomputer E. DC Fan Motor circuit has to match the Fan Motor revolution with instructed revolution. Such as... FG feedback: Faster Instruction: Slower ... Decrease pulse width FG feedback: Slower Instruction: Faster ... Increase pulse width FG pulse is also used for Fan Motor failure detection. Microcomputer will monitor FG pulse 30 seconds after start the fan motor. If there is no signal detected, it will consider that the Fan Motor was malfunction and stop the operation. In this case, LD302 on control P.W.B. will blink 12 times. (Fan Motor lock detected) R107 and IC4 are used for Fan Motor over current. – 56 – < Reference > When operation stop with LD301 blinks 12 times, it may be caused by faulty DC fan motor. In this case, please check CN6 and CN12 connection first. It makes Fan Motor Lock also if those connectors are in misconnection. DC Fan Motor has broken invites 1A Fuse burned. Please replace both DC Fan Motor and 1A Fuse together. It will makes “Fan Lock Stop” when something has disturb the Fan rotation by inserting materials into propeller fan or ice has growing inside of outdoor unit by snowing. It may make “Fan Lock Stop” by strong wind (ex. 17m/sec or above) against the Fan rotation. In this case unit will be restart again after a while. In case of “ Fan Lock Stop” even though the DC Fan Motor is rotating correctly, the possible cause in Fan Motor problem or control board problem. Stop after the Fan motor runs 2 minutes, Fan Motor may be broken. < Caution > Please take care for the electrical shock by high voltage of DC Fan Motor power source which is common with compressor when you are servicing this unit. You can not confirm the coil and wiring of Motor directly due to the built in control circuit in Fan Motor. – 57 – SERVICE CALL Q & A Model RAS-25FH5 / RAC-25YH5 RAS-35FH5 / RAC-35YH5 COOLING MODE Q1 The compressor has stopped suddenly during cooling operation. A1 Check if the indoor heat exchanger is frosted. Wait for 3-4 minutes until it is defrosted. If the air conditioner operates in cooling mode when it is cold, the evaporator may get frosted. DEHUMIDIFYING MODE Q2 A2 Fan speed is not switched over during dehumidifying operation. Q3 A3 Cool air comes from the unit during dehumidifying operation. Fans speed is normally set to LOW during dehumidifying operation. To have an operation with high dehumidifying effect, the unit operates at low fan speed. As a result, cool air comes from the unit. This phenomenon is not a fault. HEATING MODE Q4 The circulation stops occasionally during Heating mode. Q5 A4 It occurs during defrosting. Wait for 5-10 minutes until the condenser is defrosted. A5 At the beginning of heating, the fan speed remains LOW for 30 seconds. If HIGH is selected, it switches to LOW and again to MED after additional 30 seconds. A6 If temperature is high in the outdoor, heating operation may stop to protect internal devices. When the fan speed is set at HIGH or MED, the flow is actually Weak. Q6 Heating operation stops while the temperature is preset at "30". Q7 A7 When “Auto fan” mode is set, the indoor fan speed changes from HIGH through MED to LOW. This is not an error. The anti cool air function shows this phenomenon. – 58 – In the fan “Auto” mode, the unit detects the heat exchange temperature. When the temperature becomes low, the fan speed changes from HIGH, through MED to LOW. – 59 – – 60 – TROUBLE SHOOTING RAC-25YH5, 35YH5 PRECAUTIONS FOR CHECKING Indoor Controller Outdoor Controller Power Switch Point Power inlet Compressor motor WARNING Remember that voltage of 175 V is applied to the 0V line on the P.W.B. or the like as shown in the right diagram. I.P.M 400 F Point line Control P.W.B. Main P.W.B. Grounding Voltage at point A Ground voltage 350V Point B (0V line) Always keep your hands and metallic things away from the cabinet. WARNING DANGER! Donít install the ground line. When using an oscilloscope, never ground it. Donít forget that high voltage as noted in the figure above may apply to the oscilloscope. – 61 – DISCHARGE, PROCEDURE AND POWER SHUT OFF METHOD FOR POWER CIRCUIT WARNING Caution • Voltage of about 350 V is charged between the terminal of smoothing capacitors (400μF x 2). • During continuity check for each circuit part of the outdoor unit, be sure to discharge the smoothing capacitors. Discharge Procedure 1. Turn off the power of the indoor unit or pull out the power supply plug. 2. After power is turned off, wait for 10 minutes or more. Then, remove electrical parts c